Modular motor shell and manufacturing method thereof
By using modular design and aluminum alloy materials, and employing low-pressure casting and fastener connection methods, the problems of insufficient manufacturing equipment capacity, excessive weight, and limited heat dissipation performance of large cableway drive motor housings have been solved, achieving lightweight, reliable connection, and low-cost production.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-16
- Publication Date
- 2026-03-27
AI Technical Summary
The manufacturing equipment for large cableway drive motor housings is insufficient, the weight is too large, the heat dissipation performance is limited, and the quality of traditional welding is difficult to guarantee, resulting in high costs and difficulties in quality control.
The modular design breaks down the motor housing into multiple small aluminum alloy modules, which are mass-produced using low-pressure casting and connected with fasteners to form independent housing units, and then precision machined as a whole.
It solves the limitations of equipment capacity, significantly reduces weight, improves heat dissipation performance, ensures connection accuracy and reliability, reduces manufacturing costs, and adapts to the needs of motors of different specifications.
Smart Images
Figure CN121749598A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of motor technology, and more specifically to a modular motor housing and its manufacturing method. Background Technology
[0002] Passenger ropeways are widely used as an important means of transportation in scenic areas, ski resorts, and other fields. Due to their simple structure, convenient maintenance, and high efficiency, permanent magnet direct-drive motors in ropeway drive systems are increasingly being used as the main drive unit.
[0003] Cableway drive motors typically require significant torque to power the passenger gondola system, with motor power generally ranging from hundreds of kilowatts to several megawatts, and the casing diameter often exceeding 2 meters. Currently, large cableway drive motor casings are primarily manufactured using integral casting, formed from cast iron through sand casting. However, this process presents several challenges: First, there are limitations in manufacturing equipment capabilities. A 2.5-meter diameter cableway drive motor casing requires large molding equipment with a sand box capacity of over 40 cubic meters, along with corresponding melting and casting equipment. The number of domestic companies possessing this casting capability is limited, primarily concentrated in a few heavy industrial bases. Cableway equipment manufacturers often need to outsource processing, resulting in high costs and supply chain risks. Second, quality control is difficult. Large castings have long solidification times and uneven temperature distribution, easily leading to defects such as shrinkage cavities and porosity in thick-walled areas. The precision of large sand mold production is difficult to control, easily resulting in surface defects such as sand inclusions and porosity. The first-pass yield rate for cast iron parts with a diameter of over 2 meters is typically less than 70%, resulting in substantial rework and scrap costs. Some companies have attempted to assemble the shell by welding sections together, but the welding quality requirements are high, it is greatly affected by the environment, and the quality of the welds is difficult to guarantee. The cableway drive motor has strict requirements for coaxiality and roundness, and welding thermal deformation affects the geometric accuracy of the shell. Summary of the Invention
[0004] This invention provides a modular motor housing and its manufacturing method, which effectively solves the technical problems of insufficient manufacturing equipment capacity, excessive weight, and limited heat dissipation performance of large motor housings.
[0005] The present invention provides a modular motor housing, including an independent housing unit, wherein the independent housing unit includes multiple separate modules distributed circumferentially along the independent housing unit, and adjacent two separate modules are connected by a first fastener, and the separate modules are made of aluminum alloy material.
[0006] In one possible implementation, the split modules are fan-shaped structures, and multiple split modules are arranged to form an independent shell unit with a ring structure.
[0007] In one possible implementation, the split modules are provided with first connecting parts at both ends of the independent shell unit along the circumference, and the first connecting parts of two adjacent split modules are connected by a first fastener.
[0008] In one possible implementation, the first connecting part is provided with a flange connecting surface, and the flange connecting surfaces of two adjacent first connecting parts abut against each other.
[0009] In one possible implementation, the first connecting part is provided with a connecting hole, and the first fastener is a bolt pair, which passes through the connecting holes of two adjacent first connecting parts to achieve connection.
[0010] In one possible implementation, the modular unit includes a general module and a functional module. The general module only has a shell structure, while the functional module integrates external functional components on top of the shell structure.
[0011] In one possible implementation, the functional module is provided with at least one of a water inlet interface, a water outlet interface, a junction box interface, and a temperature control interface.
[0012] In one possible implementation, multiple independent housing units are provided, and the multiple independent housing units are stacked along the axial direction.
[0013] In one possible implementation, two adjacent independent housing units are connected by a second fastener.
[0014] In one possible implementation, at least one end of the independent housing unit along the axial direction is provided with a second connecting portion, and the second connecting portions of two adjacent independent housing units are connected by a second fastener.
[0015] Secondly, the present invention provides a method for manufacturing the above-mentioned modular motor housing, comprising the following steps: mass-producing multiple split modules using a low-pressure casting process, wherein the split modules are all made of aluminum alloy; assembling the multiple split modules on a fixture; using a first fastener to fix the assembled split modules into an independent housing unit; and performing overall precision machining on the independent housing unit.
[0016] One possible implementation also includes stacking multiple independent housing units axially and securing them with a second fastener.
[0017] The modular motor housing provided by this invention decomposes the traditional integral housing into multiple small-sized sub-modules. The size and weight of each sub-module are controlled within the processing capabilities of small and medium-sized equipment, enabling ordinary machine shops to undertake the manufacturing task and effectively solving the problem of equipment capacity limitations. The use of aluminum alloy for the sub-modules has significant advantages over traditional cast iron. Aluminum alloy has a density approximately 37% that of cast iron, significantly reducing the housing weight by over 60%. The thermal conductivity of aluminum alloy is four times that of cast iron, significantly improving the motor's heat dissipation performance and meeting the heat dissipation requirements of high-power-density motors. The first fastener connection, compared to welding, offers advantages such as stable connection quality and disassembly for maintenance, avoiding welding thermal deformation problems, ensuring connection accuracy, and ensuring that the overall housing geometry meets the motor's operational requirements. Sub-modules of the same specification can be mass-produced. By changing the number of sub-modules and independent housing units, the design can adapt to the needs of different motor specifications, achieving modular and standardized manufacturing. This effectively solves the technical challenges of insufficient manufacturing equipment capacity, excessive weight, and limited heat dissipation performance in large cableway drive motor housings. Attached Figure Description
[0018] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0019] Figure 1 This is a three-dimensional structural diagram of an independent shell unit provided by the present invention.
[0020] Figure 2 This is a three-dimensional structural diagram of a modular motor housing provided by the present invention.
[0021] Figure 3 This is a flowchart of a modular motor housing manufacturing method provided by the present invention.
[0022] Figure label: 1. Independent shell unit; 11. Split module; 111. First connecting part; 112. General module; 113. Functional module; 114. Reinforcing rib; 12. First fastener; 13. Second connecting part; 2. Second fastener. Detailed Implementation
[0023] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.
[0024] The following is combined Figure 1 and Figure 2 The present invention describes a modular motor housing provided in an embodiment of the invention, including an independent housing unit 1. The independent housing unit 1 includes a plurality of separate modules 11 distributed circumferentially along the independent housing unit 1. Two adjacent separate modules 11 are connected by a first fastener 12. The separate modules 11 are made of aluminum alloy material.
[0025] In this invention, the independent housing unit 1 includes multiple circumferentially distributed sub-modules 11. Adjacent sub-modules 11 are connected by a first fastener 12. The sub-modules 11 are made of aluminum alloy, breaking the traditional integral manufacturing mode of motor housings and realizing modular manufacturing of large motor housings. The modular structure allows large-size housings to be assembled from standardized small-size modules, effectively solving the problem of insufficient capacity of large casting manufacturing equipment. At the same time, the application of aluminum alloy material significantly reduces the weight of the housing and improves thermal conductivity.
[0026] Specifically, multiple separate modules 11 are distributed circumferentially along the independent shell unit 1 to form a complete ring structure. Each separate module 11 can be manufactured independently, and after manufacturing, they are interconnected by the first fastener 12. Compared with traditional cast iron, aluminum alloy has the characteristics of low density and high thermal conductivity, which reduces weight while ensuring strength. At the same time, its excellent thermal conductivity is conducive to the dissipation of heat inside the motor.
[0027] In related technologies, large motor housings are typically manufactured using a monolithic cast iron casting process, requiring large casting equipment and molds. This results in long manufacturing cycles, high costs, and the heavy weight and relatively poor thermal conductivity of cast iron. Furthermore, the trend towards larger sizes presents challenges such as equipment capacity bottlenecks and transportation limitations. In this invention, however, a modular, separate design avoids reliance on ultra-large casting equipment. Each separate module 11 can be mass-produced on standard equipment, improving manufacturing efficiency and reducing costs. The use of aluminum alloy material reduces weight while improving heat dissipation performance, and the first fastener 12 connecting adjacent separate modules 11 ensures the reliability of the overall structure.
[0028] The outer surface of the split module 11 is provided with reinforcing ribs 114, which can effectively improve the strength of the structure while maintaining the same thickness. Alternatively, it can achieve a thinner thickness while maintaining the same structural strength, thereby reducing the amount of material used and the weight.
[0029] In some embodiments, the split module 11 has a fan-shaped structure, and multiple split modules 11 form an independent shell unit 1 with a ring structure.
[0030] In this invention, the split module 11 has a fan-shaped structure, and multiple fan-shaped split modules 11 form an independent shell unit 1 with a ring structure. The use of the fan-shaped geometry makes the force distribution of each module uniform when subjected to radial force, avoiding stress concentration. At the same time, the standardized design of the fan-shaped module facilitates mass production and improves the consistency of manufacturing precision.
[0031] Specifically, the sector structure is a circular ring divided at equal angles. Each sector-shaped module 11 has the same central angle and radial dimensions. When subjected to internal radial pressure, the load is evenly distributed to the connection interface of adjacent modules through the arc surface of the sector, forming a continuous load-bearing path. The geometric symmetry of the sector-shaped modules allows for standardized manufacturing processes and simplified mold design.
[0032] In one specific embodiment, for a motor housing with a diameter of 2.5 meters, 12 fan-shaped split modules 11 with an equal angle of 30 degrees are spliced together. The geometric parameters of each module are exactly the same. During manufacturing, only one set of molds is needed to complete the production of all modules, which greatly reduces the mold investment cost compared with the traditional method. At the same time, the interchangeability between the modules is good.
[0033] In this embodiment of the invention, the fan-shaped structure ensures the geometric consistency and uniformity of force distribution of each separate module 11. After multiple fan-shaped modules are enclosed, a complete ring structure is formed, and the load-bearing characteristics are close to those of the overall structure. The first fastener 12 bears a relatively uniform load at the module connection, which improves the connection reliability.
[0034] In some embodiments, the split module 11 is provided with a first connecting portion 111 at both ends of the independent housing unit 1 along the circumferential direction, and the first connecting portions 111 of two adjacent split modules 11 are connected by a first fastener 12.
[0035] In this invention, the split module 11 is provided with a first connecting part 111 at both ends of the independent shell unit 1 along the circumference. The first connecting parts 111 of two adjacent split modules 11 are connected by a first fastener 12. The setting of the dedicated connecting part separates the connecting function from the bearing function, avoids structural interference of the connecting area to the main functional area of the shell, and provides a dedicated structural foundation for reliable connection between modules.
[0036] Specifically, the first connecting part 111 is located at both ends of the split module 11 along the circumferential direction, which is equivalent to setting a connecting structure at the straight edge of each fan-shaped module. The first connecting parts 111 of adjacent modules are connected to each other to form a connection interface. The first connecting part 111 undertakes the function of connecting load transfer between modules, while the main body of the split module 11 mainly undertakes radial pressure and other working loads.
[0037] In this embodiment of the invention, the special configuration of the first connecting part 111 realizes the separation of the connecting function and the bearing function. The first connecting part 111 can be specially designed and its strength calculated according to the connection requirements. The arrangement of the first fastener 12 is not constrained by other functional structures of the shell, and the connection reliability is guaranteed.
[0038] In some embodiments, the first connecting portion 111 is provided with a flange connecting surface, and the flange connecting surfaces of two adjacent first connecting portions 111 abut against each other.
[0039] In this invention, the first connecting part 111 is provided with a flange connecting surface. The flange connecting surfaces of two adjacent first connecting parts 111 abut against each other. The abutment of the flange surfaces forms a continuous surface contact, which has a larger contact area than line contact or point contact, and can evenly distribute the connection load. At the same time, the flatness of the flange surface ensures the sealing performance of the connection.
[0040] Specifically, the flange connection surface is a precision-machined plane, and the flange connection surfaces of adjacent first connection parts 111 fit tightly together during assembly, forming a continuous load transfer path. The contact pressure of the flange surface is generated by the preload of the first fastener 12, and the compressive stress distribution on the contact surface is relatively uniform, avoiding deformation or damage caused by excessive local stress.
[0041] In this embodiment of the invention, the flange connection surface increases the contact area, and the load transfer changes from mainly relying on bolt shear bearing to a composite bearing mode with surface contact friction bearing as the main component and bolt pre-tightening as the auxiliary component. The connection strength is significantly improved, and the sealing performance of the flange surface also provides a foundation for subsequent sealing treatment.
[0042] In some embodiments, the first connecting part 111 is provided with a connecting hole, and the first fastener 12 is a bolt pair, which passes through the connecting holes of two adjacent first connecting parts 111 to achieve connection.
[0043] In this invention, the first connecting part 111 is provided with a connecting hole, and the first fastener 12 is a bolt pair. The bolt pair passes through the connecting holes of two adjacent first connecting parts 111 to achieve connection. The bolt connection method is mature and reliable, and is convenient for assembly and subsequent maintenance. The precise machining of the connecting hole ensures the accuracy of bolt positioning and avoids stress concentration caused by assembly errors.
[0044] Specifically, the connecting hole is a circular through hole with a diameter matching the bolt shank diameter. The connecting holes of adjacent first connecting parts 111 are aligned during assembly. The bolt set includes standard parts such as bolts, nuts, and washers. The clamping force generated by the bolt pre-tightening ensures that the flange connection surfaces of adjacent first connecting parts 111 fit tightly together, and the working load is mainly transmitted through the friction of the flange surfaces. The precise machining of the connecting hole ensures the assembly accuracy between modules and avoids internal stress caused by forced assembly.
[0045] In this embodiment of the invention, the bolted connection method is highly standardized, easy to assemble, and the connection quality is easy to control. It also allows for convenient disassembly and reassembly during later maintenance. The connection hole design provides a precise positioning reference for the bolts, ensuring uniform load distribution across multiple connection points.
[0046] In some embodiments, the split module 11 includes a general module 112 and a functional module 113. The general module 112 has only a housing structure, while the functional module 113 integrates external functional components on top of the housing structure.
[0047] In this invention, the split module 11 includes a general module 112 and a functional module 113. The functional classification of the modules realizes the organic combination of standardization and customization. The general module 112 undertakes basic load-bearing functions and can be mass-produced to reduce costs. The functional module 113 integrates specific functions and can be customized according to different application needs, thereby improving the adaptability and economy of the product.
[0048] Specifically, the general-purpose module 112 has the same basic geometry and load-bearing structure, mainly providing the basic functions of the housing such as load-bearing and heat dissipation. The functional module 113, while possessing basic functions, also integrates specific functional interfaces or structures. The general-purpose module 112 and the functional module 113 maintain consistency in their connection interfaces and can be combined and configured as needed.
[0049] In some embodiments, the functional module 113 is provided with at least one of a water inlet interface, a water outlet interface, a junction box interface, and a temperature control interface.
[0050] In this invention, the functional module 113 is provided with at least one of a water inlet interface, a water outlet interface, a junction box interface, and a temperature control interface. The integrated design of the functional interfaces avoids the sealing risks caused by the scattered arrangement of multiple interfaces, while simplifying the layout of pipelines and cables, and improving the integration and reliability of the system.
[0051] Specifically, the inlet and outlet water interfaces are used for the entry and exit of the cooling medium, the junction box interface is used for electrical connections, and the temperature control interface is used for the installation of the temperature sensor. These interfaces can be set individually or in combination on the same functional module 113 according to actual needs. The standardized design of the interfaces facilitates connection with external pipelines and cables.
[0052] In one specific embodiment, a large cooling motor used in a data center requires a water cooling system and a temperature monitoring system. The water inlet, water outlet and temperature control interface are integrated into a single functional module 113, forming a closed loop in the cooling water circuit. The temperature control interface monitors the water temperature locally, resulting in a high degree of system integration, simple piping, and convenient maintenance.
[0053] In this embodiment of the invention, the integrated design of the functional module 113 centrally sets up the relevant functional interfaces, which reduces the pipeline length and connection points, reduces the system complexity, facilitates maintenance operations, and simplifies the fault handling process by allowing modular replacement of the functional module 113.
[0054] Highly integrated solution: All or some of the above-mentioned functional interfaces (such as junction box interface and temperature control interface) can be integrated into the same functional module 113 to form a "multi-functional integrated module". This reduces the number of functional modules 113 and is suitable for applications with compact structural space.
[0055] Further separation options: A certain function can also be further separated. For example, the single "water inlet and outlet module" can be split into independent "water inlet module" and "water outlet module" to optimize the piping layout of the cooling system and reduce flow resistance.
[0056] In some embodiments, multiple independent housing units 1 are provided, and the multiple independent housing units 1 are stacked along the axial direction.
[0057] In this invention, multiple independent housing units 1 are provided, and the multiple independent housing units 1 are stacked along the axial direction. The modular design of axial stacking allows the axial length of the motor to be flexibly adjusted according to the power requirements. Compared with the fixed length design, it has better product serialization capability, and the segmented manufacturing reduces the requirements for the size of the manufacturing equipment.
[0058] Specifically, each independent housing unit 1 is a complete annular structure with the same radial dimensions and connection interfaces. Multiple independent housing units 1 are arranged sequentially along the motor axis to form a complete housing of the required length. The number of units stacked axially can be determined according to the motor's power requirements and length requirements, thus realizing the modular configuration of the product.
[0059] In one specific embodiment, for motor series with different power, the basic motor diameter is the same, and the power output is adjusted by changing the axial length. After adopting the axial stacking design, the small power motor adopts 2 independent housing units 1, and the large power motor adopts 4 independent housing units 1, realizing the standardized manufacturing of serialized products.
[0060] In this embodiment of the invention, the standardized design of the independent housing unit 1 enables motors of different lengths to be realized through different combinations of standard units. One set of manufacturing tooling can support multiple product specifications, and the segmented manufacturing of multiple independent housing units 1 solves the manufacturing problem of long-size equipment.
[0061] In some embodiments, two adjacent independent housing units 1 are connected by a second fastener 2.
[0062] In this invention, two adjacent independent housing units 1 are connected by a second fastener 2. The mechanical connection between the independent units ensures the integrity of the multi-segment structure. The second fastener 2 bears the axial connection load, ensuring that each independent housing unit 1 works together. The standardization of the connection method simplifies the assembly process.
[0063] Specifically, the second fastener 2 is used to connect adjacent independent shell units 1, bearing the axial force and torque transmission between units, ensuring that the multiple shell sections deform in a coordinated manner as a whole structure during operation. The selection and arrangement of the second fastener 2 are determined according to the magnitude and distribution of the axial load, and the connection strength meets the stress requirements of the overall structure.
[0064] In this embodiment of the invention, the connection method of the second fastener 2 is similar to that of the first fastener 12, the process is uniform, and it is easy to control the quality. The connection strength of adjacent independent shell units 1 is designed and controlled by the specifications and quantity of the second fastener 2, and the connection reliability is guaranteed.
[0065] In some embodiments, at least one end of the independent housing unit 1 along the axial direction is provided with a second connecting portion 13, and the second connecting portions 13 of two adjacent independent housing units 1 are connected by a second fastener 2.
[0066] In this invention, at least one end of the independent housing unit 1 along the axial direction is provided with a second connecting part 13. The second connecting parts 13 of two adjacent independent housing units 1 are connected by a second fastener 2. The dedicated axial connection structure provides a reliable connection basis for the combination of multiple units. The separation design of the second connecting part 13 from the main load-bearing part of the housing avoids the influence of the connection load on the accuracy of the housing.
[0067] Specifically, the second connecting part 13 is located at the axial end of the independent housing unit 1, forming a dedicated structure for axial connection. The second connecting parts 13 of adjacent independent housing units 1 are connected by the second fastener 2 after they are mated together. The second connecting part 13 undertakes the axial connection function, while the main body of the independent housing unit 1 undertakes radial load-bearing and other functions.
[0068] In some embodiments, the split module 11 is manufactured using a low-pressure casting process.
[0069] In this invention, the split module 11 is manufactured using a low-pressure casting process. Compared with traditional sand casting, low-pressure casting has higher dimensional accuracy and better surface quality. The low pressure during the casting process makes the aluminum alloy liquid filling mold stable, the microstructure dense, reduces casting defects, and improves the mechanical properties and machining accuracy of the split module 11.
[0070] Specifically, low-pressure casting uses relatively low casting pressure, typically 0.02-0.06 MPa. Under pressure, the molten metal smoothly fills the mold cavity from bottom to top, avoiding the impact and splashing that occurs during gravity pouring. This results in a dense casting with a high surface finish. The presence of casting pressure also helps eliminate shrinkage defects and improves the mechanical properties of the casting.
[0071] In some embodiments, the functional module 113 is configurable in a circumferential position.
[0072] In this invention, the functional module 113 is configurable in a circumferential position. The adjustability of the installation position of the functional module 113 allows the same housing to adapt to different external connection requirements. The direction of the functional interface can be flexibly adjusted according to the actual situation of the project's pipeline layout and installation space, thereby improving the product's versatility and installation adaptability.
[0073] Specifically, functional module 113 and general module 112 use the same connection interface and can be installed at any circumferential position in the independent housing unit 1. The circumferential position of functional module 113 is determined based on factors such as the external pipeline routing and equipment installation direction. Position adjustment is achieved by changing the circumferential position of functional module 113 during assembly.
[0074] In some embodiments, the diameter of the modular motor housing is greater than 2 meters.
[0075] In this invention, the diameter of the modular motor housing is greater than 2 meters. For the application of large-diameter motors, the advantages of modular design are more prominent. Traditional integral manufacturing methods face equipment capacity bottlenecks and transportation restrictions when the size is large, while the modular solution effectively solves the manufacturing problem of large motor housings.
[0076] Specifically, motor housings with a diameter greater than 2 meters are considered large structural components. Their overall manufacturing requires large casting or welding equipment, transportation is subject to road height and width restrictions, and on-site installation requires large lifting equipment. The modular, split structure breaks down the large housing into smaller, easier-to-manufacture modules.
[0077] The present invention provides a large permanent magnet direct drive motor, including the modular motor housing described above.
[0078] In this invention, the large permanent magnet direct drive motor includes the aforementioned modular motor housing. The combination of the modular housing and the permanent magnet direct drive motor fully leverages the technical advantages of both. The permanent magnet direct drive motor is characterized by high efficiency and maintenance-free operation, while the modular housing provides lightweight and easy-to-install structural support. The combination of the two enhances the overall performance of the large motor system.
[0079] Specifically, permanent magnet direct drive motors use permanent magnets to provide the magnetic field, eliminating the need for an excitation system. This simplifies the structure, increases efficiency, and makes them suitable for large-scale applications such as wind power generation. The modular motor housing provides mechanical support and protection for the permanent magnet direct drive motor. The lightweight properties of aluminum alloy reduce the overall weight of the motor, and the modular structure facilitates the manufacturing and installation of large motors.
[0080] like Figure 3 As shown, the present invention provides a method for manufacturing the above-mentioned modular motor housing, comprising the following steps: mass-producing multiple split modules 11 using a low-pressure casting process, wherein each split module 11 is made of aluminum alloy; assembling the multiple split modules 11 on a fixture; using a first fastener 12 to fix the assembled split modules 11 into an independent housing unit 1; and performing overall precision machining on the independent housing unit 1.
[0081] In this invention, the manufacturing method includes the following steps: mass-producing multiple split modules 11 using a low-pressure casting process; assembling the multiple split modules 11 on a fixture; using a first fastener 12 to fix the assembled split modules 11 into an independent shell unit 1; and performing overall precision machining on the independent shell unit 1. The standardized process of manufacturing ensures the stability of product quality, mass production reduces the cost per unit, and the step-by-step process arrangement improves manufacturing efficiency.
[0082] Specifically, the low-pressure casting process completes the molding of the modular components 11 during the mass production stage; the fixture assembly stage ensures the assembly accuracy of each module; the first fastener 12 connection stage forms the overall structure of the independent shell unit 1; and the overall finishing stage ensures the dimensional accuracy and surface quality of the final product. Each process step has a clearly defined function, facilitating quality control.
[0083] In one specific embodiment, the motor housing with a diameter of 2.8 meters is produced by assembling 8 identical fan-shaped modular modules 11. Mass casting reduces the cost of a single module, fixture assembly ensures the relative positional accuracy of each module, bolt connection simplifies assembly, and final overall finishing ensures key accuracy requirements such as inner diameter roundness.
[0084] In related technologies, the manufacturing of large motor housings typically employs integral casting or welding processes, which are time-consuming, costly, and difficult to control in terms of quality. Furthermore, the overall machining requires large equipment, making it challenging to guarantee machining accuracy. In contrast, this invention utilizes a phased manufacturing process that breaks down the complex manufacturing of large components into a combination of multiple simpler processes. Quality control at each stage is relatively easy, and the economies of scale from mass production reduce costs. Overall finishing is performed after module assembly, ensuring critical precision requirements are met.
[0085] In some embodiments, the method further includes: stacking multiple independent housing units 1 axially and securing them with a second fastener 2.
[0086] In this invention, the manufacturing method also includes the step of stacking multiple independent housing units 1 axially and fixing them with a second fastener 2. The axial stacking process enables the segmented manufacturing of ultra-long motor housings, effectively solving the manufacturing problem of large equipment. At the same time, segmented manufacturing reduces the size requirements of individual manufacturing equipment.
[0087] The device embodiments described above are merely illustrative. The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Those skilled in the art can understand and implement this without any creative effort.
[0088] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. A modular motor housing, characterized in that, It includes an independent housing unit (1), which includes a plurality of split modules (11) distributed circumferentially along the independent housing unit. Two adjacent split modules (11) are connected by a first fastener (12). The split modules (11) are made of aluminum alloy material.
2. The modular motor housing according to claim 1, characterized in that, The split module (11) has a fan-shaped structure, and multiple split modules (11) form an independent shell unit (1) with a ring structure.
3. The modular motor housing according to claim 1, characterized in that, The split module (11) is provided with a first connecting part (111) at both ends of the independent shell unit (1) along the circumference. The first connecting parts (111) of two adjacent split modules (11) are connected by the first fastener (12).
4. The modular motor housing according to claim 3, characterized in that, The first connecting part (111) is provided with a flange connecting surface, and the flange connecting surfaces of two adjacent first connecting parts (111) abut against each other.
5. The modular motor housing according to claim 3, characterized in that, The first connecting part (111) is provided with a connecting hole, and the first fastener (12) is a bolt pair. The bolt pair passes through the connecting holes of two adjacent first connecting parts (111) to achieve connection.
6. The modular motor housing according to claim 1, characterized in that, The split module (11) includes a general module (112) and a functional module (113). The general module (112) has only a shell structure, and the functional module (113) integrates external functional components on the basis of the shell structure.
7. The modular motor housing according to claim 6, characterized in that, The functional module (113) is provided with at least one of the following: water inlet interface, water outlet interface, junction box interface, and temperature control interface.
8. The modular motor housing according to any one of claims 1-7, characterized in that, Multiple independent housing units (1) are provided, and multiple independent housing units (1) are stacked along the axial direction.
9. The modular motor housing according to claim 8, characterized in that, The two adjacent independent housing units (1) are connected by a second fastener (2).
10. A method for manufacturing a modular motor housing as described in any one of claims 1-9, characterized in that, Includes the following steps: Multiple modular units (11) are mass-produced using a low-pressure casting process, and all modular units (11) are made of aluminum alloy. Multiple separate modules (11) are assembled on a fixture; The assembled split modules (11) are fixed into an independent shell unit (1) using the first fastener (12); The independent housing unit (1) is subjected to overall precision machining.